Compositions and methods for producing a lubricant

ABSTRACT

Compositions for lubricants and methods for producing the same using spherical bismuth powder and spherical copper powder particles are disclosed. In at least one embodiment, the lubricant includes a base oil, a grease, a copper powder, comprising at least one spherical particle, and a bismuth powder, comprising at least one spherical particle. The lubricant can be used as an engine oil, a gear oil, a grease lubricant, or a spray lubricant. When applying the lubricant to an internal combustible engine, the heat and pressure within the engine compresses the lubricant to infuse the copper and bismuth powder particles to the internal surface of the engine. When used in internal combustible engines, the disclosed lubricants deliver outstanding wear resistance, improve gas mileage, extend interval times needed for oil changes, and also reduce engine exhaust emission.

PRIORITY

The present International Patent Application is related to, and claims the priority benefit of, U.S. Provisional Patent Application Ser. No. 61/958,709, filed Aug. 5, 2013, the contents of which are hereby incorporated into the present disclosure in their entirety.

BACKGROUND

Combustion engines, such as those within automobiles, lawn mowers, engine-generators, and other machines, contain parts which move against each other causing friction. Friction wastes otherwise useful power by converting kinetic energy to heat. It also wears away the moving parts, which could lead to lower efficiency and degradation of the engine. Thus, continuous friction in an engine may lead to an increase in fuel consumption, decrease in power output, and can lead to engine failure.

Lubricating compositions, greases, and other fluids are commonly used in combustion engines to protect the engine by reducing wear on the moving parts. Lubricants create a separating film between surfaces of adjacent moving parts to minimize direct contact between them, thereby decreasing heat caused by friction and reducing wear, thus protecting the engine. Lubricants also clean, inhibit corrosion, improve sealing, and cool the engine by carrying heat away from the moving parts.

Many lubricants are generally composed of a base oil plus a variety of additives to improve certain properties. Some of the benefits of additives include increasing viscosity, increasing detergency to minimize sludge buildup, improving extreme pressure (EP) performance, increasing resistance to corrosion and oxidation, and decreasing contamination. Metal alloys, composites and pure metals are commonly used as additives for lubricants. For instance, lead is a common EP additive for lubricating oils and greases and is effective in decreasing friction and inhibiting corrosion. (Richard W. Hein, Evaluation of Bismuth Napthenate as an EP additive, November 2000). However, lead is a toxic and hazardous material and is harmful on the environment and to human health. Id.; European Copper Institute, September 2007; Environmental Protection Agency (EPA), 2014. Numerous attempts have been made to create lubricants having metal particles therein similar to lead to improve the lubricating qualities and the wear resistance of the lubricants in engines and other machines. However, none have been successful to date. Therefore, there is a need for a non-hazardous additive replacement for lead in lubricants.

BRIEF SUMMARY

The disclosed lubricant compositions and methods for producing the same use spherical particles of both copper powder and bismuth powder as a replacement for lead. When used in internal combustible engines, such as those within automobiles, lawn mowers, engine-generators, and other machines, the disclosed lubricants deliver outstanding wear resistance, improve gas mileage, extend interval times needed for oil changes, and also reduce engine exhaust emission.

In one embodiment, a lubricant is provided. The lubricant includes a base oil, a grease, a copper powder, comprising at least one spherical particle, and a bismuth powder, comprising at least one spherical particle. In one exemplary embodiment, the copper powder is between 0.1% and 60% of the total weight of the lubricant. In yet another exemplary embodiment, the bismuth powder is between 0.1% and 60% of the total weight of the lubricant. In yet another exemplary embodiment, at least one spherical particle of copper powder is about 4.0 μm to 176.0 μm in size. In at least one exemplary embodiment, the D50 particle size of at least one particle of the copper powder is about 8 μm to 13 μm. In another embodiment, at least one spherical particle of the bismuth powder is about 0.9 μm to 32.0 μm in size. In yet another exemplary embodiment, the D50 size of at least one particle of the bismuth powder is about 5.0 μm to 15 μm.

In at least one exemplary embodiment, the lubricant is an engine oil. In one embodiment where the lubricant is an engine oil, the base oil comprises a shear stabile polymer and at least one additive. In at least one exemplary embodiment, the lubricant is a gear oil. In one embodiment where the lubricant is a gear oil, the base oil comprises a top-treat additive package. In another at least one exemplary embodiment, the lubricant is a grease. In one embodiment where the lubricant is a grease, the grease comprises a synthetic lubricating grease comprising a lithium complex. In yet another at least one exemplary embodiment, the lubricant is a spray lubricant.

The disclosed embodiments also include methods for producing a lubricant. In at least one aspect of the present disclosure, the method includes the steps of selecting at least one base oil, selecting at least one grease, adding a first quantity of the at least one base oil to a first quantity of the at least one grease in a mixing container, adding a copper powder to the mixing container, wherein the copper powder comprises at least one spherical particle, adding a bismuth powder to the mixing container, wherein the bismuth powder comprises at least one spherical particle, and mixing the first quantity of the at least one base oil, the first quantity of the at least one grease, the copper powder, and the bismuth powder in the mixing container until well blended to form a lubricant composition. In at least one embodiment, the method includes the step of mixing the first quantity of the at least one base oil and the first quantity of the at least one grease in the mixing container prior to adding the copper powder and bismuth powder to the mixing container.

In at least one embodiment, the method includes the step of mixing the lubricant composition with a second quantity of the base oil to form an engine or gear oil lubricant. In at least one exemplary embodiment, the at least one base oil and at least one grease is mixed in the mixing container at a high speed for 20 minutes; wherein the first quantity of the at least one base oil, the at least one grease, the spherical copper powder and the spherical bismuth powder are mixed in the mixing container at a high speed for 45 minutes; and wherein the lubricant and the second quantity of the base oil are mixed in the mixing container for 20 minutes.

In yet another at least one embodiment, the method includes the step of mixing the lubricant composition with a second quantity of grease to form a grease lubricant. In at least one embodiment, the method includes the step of mixing the lubricant composition with mineral spirits to form a spray lubricant.

In at least one aspect of the present disclosure the method further includes the steps of applying the lubricant composition to an engine comprising at least one metal surface, applying heat and pressure within the engine to compress the lubricant composition, wherein compressing the lubricant composition infuses the copper powder and the bismuth powder within the lubricant composition to the at least one metal surface of the engine, and coating the at least one metal surface of the engine with the infused copper powder and bismuth powder. Other embodiments are also disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments and other features, advantages and disclosures contained herein, and the manner of attaining them, will become apparent and the present disclosure will be better understood by reference to the following description of various exemplary embodiments of the present disclosure taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a flow diagram of a method for producing a lubricant that is an engine oil.

FIG. 2 is a flow diagram of a method for producing a lubricant that is a gear oil.

FIG. 3 is a flow diagram of a method for producing a lubricant that is a grease.

FIG. 4 is a flow diagram of a method for producing a lubricant that is a spray lubricant.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of this disclosure is thereby intended.

In at least one embodiment of the present disclosure, the lubricant includes a base oil, a grease, a copper powder, comprising at least one spherical particle, and a bismuth powder, comprising at least one spherical particle. An exemplary embodiment of a lubricant of the present disclosure is shown in FIG. 1. FIG. 1 is a flow diagram of a method 100 for producing a lubricant according to at least one embodiment of the present disclosure. Specifically, the lubricant disclosed in FIG. 1 is directed to the method of producing an engine oil lubricant 100. In at least one embodiment according to the present disclosure, the method 100 includes the step of selecting at least one base oil 102. The base oil selected 102 may comprise a shear stabile polymer and at least one additive. The selected base oil 102 may include, but is not limited to, Altra Oil Treatment 250. The Altra Oil 250 can be used in any engine oil, such as in gasoline or diesel engines. Altra Oil 250 contains antiwear and detergent/dispersant additives. Altra Oil 250 reduces friction, engine wear, contains detergent/dispersant reducing deposits, neutralizes acids, compatible with all types of motor oil, and contains seal swell.

In at least one embodiment according to the present disclosure, the method 100 includes the step of selecting at least one grease 104. The grease selected 104 may be selected from, but is not limited to: SLC HV 00 Purple (Chemtool, Inc.); Duralube EP-0 (Chemtool, Inc.); Duralube EP-1 (Chemtool, Inc.); Duralube EP-2 (Chemtool, Inc.); and/or an Over Base Calcium Sulfonate grease, such as Alpha 2000 (Chemtool, Inc.). In one exemplary embodiment of the present disclosure, the grease selected 104 is an EP-2 grease.

The SLC HV 00 Purple grease is a premium, lithium complex grease formulated with synthetic hydrocarbon fluids. It exhibits low temperature performance to temperatures of −40 degrees Fahrenheit and has been formulated with an additive package which insures high film strength, EP, corrosion protection, and anti-wear properties. This grease is used for grease filled industrial gear cases, subject to high temperatures. Duralube EP-0, EP-1, and EP-2 are lithium complex greases formulated with quality base oils and fortified with rust and oxidation inhibitors as well as EP additives. They are water resistant greases and have a dropping point of over 500 degrees Fahrenheit allowing them to perform at high temperatures.

The Over Base Calcium Sulfonate grease, such as Alpha 2000, may come in different grades, such as EP1 or EP2, etc. It is a calcium based grease that performs at extremely high temperatures. For instance, Alpha 2000 does not become fluid at temperatures approaching 600° F. and after cooling to room temperature, it returns to its original grease structure. Alpha 2000 may be used in a variety of applications for automotive, industrial, construction, agricultural, railroad, and mining operations. Specific applications include all chassis points for automotive, wheel bearings, fifth wheels, king pins, anti-friction bearings, low and high speed journal bearings, oven conveyors, electric motor bearings, steel mill roller bearings, and on form and earth-moving equipment. Alpha 2000 is also excellent for use in marine type applications where water washout and corrosion are of primary concern. The benefits of using an Over Base Calcium Sulfonate grease include water resistance and corrosion protection. It contains no heavy metals or other harmful or environmentally undesirable additives such as sulfur, phosphorus, chlorine, zinc, phenols, antimony, barium or lead.

In at least one embodiment according to the present disclosure, the method 100 includes the step of adding a first quantity of the at least one base oil 106 to a first quantity of the at least one grease 108 in a mixing container 110. The mixing container may include, but is not limited to, a metal or plastic drum, vat, or container. In particular, a stainless steel or aluminum vat, drum, or container may be used.

In at least one embodiment according to the present disclosure, the method 100 includes the step of adding a copper powder to the mixing container, wherein the copper powder comprises at least one spherical particle 114. The copper powder may include, but is not limited to, copper powder purchased from ACuPowder International, LLC (MSDS Number C-801 Copper Powder-American Chemet Corporation (Chem Copp 1700 FPM)). The Copper 1700 FPM has a D50 in the range of about 8.0 μm to 13.0 μm. The spherical shaped copper powder particles are about 4.0 μm to 176.0 μm in size. The percent of copper powder used may range from 0.1% up to 60.0% of the total weight of the engine oil lubricant.

In at least one embodiment according to the present disclosure, the method 100 includes the step of adding a bismuth powder to the mixing container, wherein the bismuth powder comprises at least one spherical particle 116. The bismuth powder may include, but is not limited to, bismuth powder purchased from ACuPowder International, LLC (MSDS Number B-101 Bismuth Powder-American Chemet Corporation (301A Bi)). The 301A Bi has a D50 in the range of about 5.0 μm to 15 μm. The spherical shaped bismuth powder particles are about 0.9 μm to 32.0 μm in size. The percent of bismuth powder used may range from 0.1% up to 60.0% of the total weight of the engine oil lubricant.

In at least one embodiment according to the present disclosure, the method 100 includes the step of mixing the first quantity of the at least one base oil 106 and the first quantity of the at least one grease 108 in the mixing container prior to adding the copper powder 114 and bismuth powder 116 to the mixing container 112. In at least one embodiment according to the present disclosure, the method 100 includes the step of mixing the first quantity of the at least one base oil 106, the first quantity of the at least one grease 108, the copper powder 114, and the bismuth powder 116 in the mixing container until well blended to form a lubricant composition 118. Mixing may occur at any speed fast enough to disperse the copper and bismuth powders. The mixing speed may include, but is not limited to, 500-2000 rpm, and preferably 500-1500 rpm at a temperature less than 140 degrees Fahrenheit.

In at least one embodiment according to the present disclosure, the method 100 includes the step of mixing the lubricant composition 118 with a second quantity of the base oil 120 to form an engine oil lubricant 122. In at least one exemplary embodiment according to the present disclosure, the at least one base oil 106 and at least one grease 108 is mixed in the mixing container at a high speed for twenty (20) minutes 112; wherein the first quantity of the at least one base oil 106, the first quantity of the at least one grease 108, the spherical copper powder 114, and the spherical bismuth powder 116 are mixed in the mixing container at a high speed for forty-five (45) minutes 118; and wherein the lubricant composition 118 and the second quantity of the base oil 120 are mixed in the mixing container for twenty (20) minutes 122.

In another embodiment of the present disclosure, the method 100 further includes the step of applying the engine oil lubricant to an engine comprising at least one metal surface 124. In at least one aspect of the present disclosure, the method 100 includes the step of applying heat and pressure within the engine to compress the engine oil lubricant, wherein compressing the engine oil lubricant infuses the copper powder and the bismuth powder within the engine oil lubricant to the at least one metal surface of the engine 126. The heat and pressure applied to the engine include normal temperatures and pressures as found under normal conditions of running an engine. The types of engines may include combustible engines, such as gasoline, diesel, propane and natural gas engines within automobiles, lawn mowers, engine-generators, and other machines. Smaller engines require a smaller dosage of the engine oil. For instance, small engines require 1 ounce per quart of engine oil lubricant; 4 and 6 cylinder engines require 4 ounces of engine oil lubricant; 8 cylinder engines require 6 ounces of engine oil lubricant; and heavy equipment, trucks, and tractors require 16 ounces.

In at least one aspect of the present disclosure, the method 100 includes the step of coating the at least one metal surface of the engine with the infused copper powder and bismuth powder 128. The application of heat and pressure within the engine to infuse the copper powder and bismuth powder 126 coats the at least one metal surface of the engine. After coating the at least one metal surface of the engine with the infused copper powder and bismuth powder 128, the at least one metal surface of the engine has a bronze color from the impregnated particles of copper and bismuth. The engine oil lubricant plates the friction surfaces filling in minor imperfections, scratches and scars in the metal surfaces being treated, making a smooth surface reducing friction and reducing wear from taking place. The engine oil lubricant acts as millions of microscopic ball bearings providing a barrier between two metal surfaces reducing metal on metal contact, which is the main cause of wear and friction. It also provides a detergent/cleaning action as it circulates through the engine and scrubs away oil sludge and deposits built up on components, restoring engine cavities to like new cleanliness.

The benefits of the engine oil lubricant include, but are not limited to, increasing fuel economy, reducing oil consumption, reducing emissions, reducing operating temperatures, extending engine life and increasing reliability, reducing wear and scoring on all component surfaces, keeping equipment operating at peak performance, reducing friction and providing higher performance under load, improving compression and horsepower, neutralizing acids to reduce oil breakdown, providing better cold starts, and providing unique plating action on surfaces and protecting against lubrication starvation. The engine oil lubricant does not contain any lead, PTFE, chlorinated paraffins, or antimony components.

Another exemplary embodiment of a lubricant of the present disclosure is shown in FIG. 2. FIG. 2 is a flow diagram of a method 200 for producing a lubricant according to at least one embodiment of the present disclosure. Specifically, the lubricant disclosed in FIG. 2 is directed to the method of producing a gear oil lubricant 200. The gear oil lubricant as disclosed is a unique and outstanding concentrated oil supplement for gear boxes, hydraulics, differentials, manual transmissions, transfer cases, power steering, and some compressors. In at least one embodiment according to the present disclosure, the method 200 includes the step of selecting at least one base oil 202. The base oil selected 202 may comprise a top-treat additive package. The selected base oil 202 may include, but is not limited to, HiTEC 397. HiTEC 397 is a top-treat additive for gear oils designed to impart frictional characteristics needed by limited slip axles. It has been optimized to bring the required friction performance needed to minimize chatter by promoting smooth clutch engagement. It minimizes NVH associated with momentary cyclic torque loss, satisfies torque/power requirements necessary for modern vehicles, and maintains friction coefficient level over life of fluid for good torque transfer.

In at least one embodiment according to the present disclosure, the method 200 includes the step of selecting at least one grease 204. The grease selected 204 may include, but is not limited to: SLC HV 00 Purple (Chemtool, Inc.); Duralube EP-0 (Chemtool, Inc.); Duralube EP-1 (Chemtool, Inc.); Duralube EP-2 (Chemtool, Inc.); and/or an Over Base Calcium Sulfonate grease, such as Alpha 2000 (Chemtool, Inc.). In one exemplary embodiment of the present disclosure, the grease selected 204 is an EP-2 grease.

The SLC HV 00 Purple grease is a premium, lithium complex grease formulated with synthetic hydrocarbon fluids. It exhibits low temperature performance to temperatures of −40 degrees Fahrenheit and has been formulated with an additive package which insures high film strength, EP, corrosion protection, and anti-wear properties. This grease is used for grease filled industrial gear cases, subject to high temperatures. Duralube EP-0, EP-1, and EP-2 are lithium complex greases formulated with quality base oils and fortified with rust and oxidation inhibitors as well as EP additives. They are water resistant greases and have a dropping point of over 500 degrees Fahrenheit allowing them to perform at high temperatures.

The Over Base Calcium Sulfonate grease, such as Alpha 2000, may come in different grades, such as EP1 or EP2, etc. It is a calcium based grease that performs at extremely high temperatures. For instance, Alpha 2000 does not become fluid at temperatures approaching 600° F. and after cooling to room temperature, it returns to its original grease structure. Alpha 2000 may be used in a variety of applications for automotive, industrial, construction, agricultural, railroad, and mining operations. Specific applications include all chassis points for automotive, wheel bearings, fifth wheels, king pins, anti-friction bearings, low and high speed journal bearings, oven conveyors, electric motor bearings, steel mill roller bearings, and on form and earth-moving equipment. Alpha 2000 is also excellent for use in marine type applications where water washout and corrosion are of primary concern. The benefits of using an Over Base Calcium Sulfonate grease include water resistance and corrosion protection. It contains no heavy metals or other harmful or environmentally undesirable additives such as sulfur, phosphorus, chlorine, zinc, phenols, antimony, barium or lead.

In at least one embodiment according to the present disclosure, the method 200 includes the step of adding a first quantity of the at least one base oil 206 to a first quantity of the at least one grease in a mixing container 210. The mixing container may include, but is not limited to, a metal or plastic drum, vat, or container. In particular, a stainless steel or aluminum vat, drum, or container may be used.

In at least one embodiment according to the present disclosure, the method 200 includes the step of adding a copper powder to the mixing container, wherein the copper powder comprises at least one spherical particle 214. The copper powder may include, but is not limited to, copper powder purchased from ACuPowder International, LLC (MSDS Number C-801 Copper Powder-American Chemet Corporation (Chem Copp 1700 FPM)). The Copper 1700 FPM has a D50 in the range of about 8.0 μm to 13.0 μm. The spherical shaped copper powder particles are about 4.0 μm to 176.0 μm in size. The percent of copper powder used may range from 0.1% up to 60.0% of the total weight of the gear oil lubricant.

In at least one embodiment according to the present disclosure, the method 200 includes the step of adding a bismuth powder to the mixing container, wherein the bismuth powder comprises at least one spherical particle 216. The bismuth powder may include, but is not limited to, bismuth powder purchased from ACuPowder International, LLC (MSDS Number B-101 Bismuth Powder-American Chemet Corporation (301A Bi)). The 301A Bi has a D50 in the range of about 5.0 μm to 15 μm. The spherical shaped bismuth powder particles are about 0.9 μm to 32.0 μm in size. The percent of bismuth powder used may range from 0.1% up to 60.0% of the total weight of the gear oil lubricant.

In at least one embodiment according to the present disclosure, the method 100 includes the step of mixing the first quantity of the at least one base oil 206 and the first quantity of the at least one grease 208 in the mixing container prior to adding the copper powder 214 and bismuth powder 216 to the mixing container 212. In at least one embodiment according to the present disclosure, the method 200 includes the step of mixing the first quantity of the at least one base oil 206, the first quantity of the at least one grease 208, the copper powder 214, and the bismuth powder 216 in the mixing container until well blended to form a lubricant composition 218. Mixing may occur at any speed fast enough to disperse the copper and bismuth powders. The mixing speed may include, but is not limited to, 500-2000 rpm, and preferably 500-1500 rpm at a temperature less than 140 degrees Fahrenheit.

In at least one embodiment according to the present disclosure, the method 200 includes the step of mixing the lubricant composition 218 with a second quantity of the base oil 220 to form a gear oil lubricant 222. In at least one exemplary embodiment according to the present disclosure, the at least one base oil 206 and at least one grease 208 is mixed in the mixing container at a high speed for twenty (20) minutes 212; wherein the first quantity of the at least one base oil 206, the first quantity of the at least one grease 208, the spherical copper powder 214 and the spherical bismuth powder 216 are mixed in the mixing container at a high speed for forty-five (45) minutes 218; and wherein the lubricant composition 218 and the second quantity of the base oil 220 are mixed in the mixing container for twenty (20) minutes 222.

In another at least one embodiment of the present disclosure, the method 200 further includes the step of applying the lubricant composition to an engine comprising at least one metal surface 224. In at least one aspect of the present disclosure, the method 200 includes the step of applying heat and pressure within the engine to compress the lubricant composition, wherein compressing the lubricant composition infuses the copper powder and the bismuth powder within the lubricant composition to the at least one metal surface of the engine 226. The heat and pressure applied to the engine include normal temperatures and pressures as found under normal conditions of running an engine. The types of engines may include combustible engines, such as those within automobiles, lawn mowers, engine-generators, and other machines. For hydraulics, a dosage of gear oil of 1 ounce per quart is required. For regular duty gear boxes, 2 ounces per quart, and for heavy load/high torque gear boxes, 3 ounces per quart of the gear oil lubricant is required.

In at least one aspect of the present disclosure, the method 200 includes the step of coating the at least one metal surface of the engine with the infused copper powder and bismuth powder 228. The application of heat and pressure within the engine to infuse the copper powder and bismuth powder 226 coats the at least one metal surface of the engine. After coating the at least one metal surface of the engine with the infused copper powder and bismuth powder 228, the at least one metal surface of the engine has a bronze color from the impregnated particles of copper and bismuth. The gear oil is for use in any non-friction based gear application using oil for lubrication, such as industrial gear boxes, hydraulics, differentials, manual transmissions, transfer cases, power steering, sliding ways and some compressors. The gear oil lubricant plates the friction surfaces filling in minor imperfections, scratches and scars in the metal surfaces being treated, making a smooth surface reducing friction and reducing wear from taking place. The gear oil lubricant acts as millions of microscopic ball bearings providing a barrier between two metal surfaces reducing metal on metal contact which is the main cause of wear and friction. It also provides a detergent/cleaning action as it circulates through the engine and scrubs away oil sludge and deposits built up on components, restoring engine cavities to like new cleanliness.

The benefits of the gear oil lubricant according to the present disclosure include, but are not limited to, reducing operating temperatures, improving power, providing better starts, reducing power required for startup, dramatically extending equipment life and increasing reliability, reducing wear and scoring on all component surfaces, keeping equipment operating at peak performance, reducing friction and providing high performance under load, neutralizing acids to reduce oil breakdown, and unique plating action on surfaces for protecting against lubrication starvation. The gear oil lubricant according to the present disclosure does not contain any lead, PTFE, chlorinated paraffins, or antimony components.

In yet another exemplary embodiment of a lubricant of the present disclosure is shown in FIG. 3. FIG. 3 is a flow diagram of a method 300 for producing a lubricant according to at least one embodiment of the present disclosure. Specifically, the lubricant disclosed in FIG. 3 is directed to the method of producing a grease 300. In at least one embodiment according to the present disclosure, the method 300 includes the step of selecting at least one base oil 302. The base oil selected 302 may include, but is not limited to, Synative ES 2900. Synative ES 2900 is an ester base oil containing highly polar ester functional groups. Synative ES 2900 is compatible with lithium greases and is used primarily as a dispersing oil.

In at least one embodiment according to the present disclosure, the method 300 includes the step of selecting at least one grease 304. The grease 304 selected may include, but is not limited to, a synthetic lubricating grease comprising a lithium complex. The grease 304 may be selected from, but is not limited to: SLC HV 00 Purple (Chemtool, Inc.); Duralube EP-0 (Chemtool, Inc.); Duralube EP-1 (Chemtool, Inc.); Duralube EP-2 (Chemtool, Inc.); and/or an Over Base Calcium Sulfonate grease, such as Alpha 2000 (Chemtool, Inc.). In one exemplary embodiment of the present disclosure, the grease selected 304 is an EP-2 grease.

The SLC HV 00 Purple grease is a premium, lithium complex grease formulated with synthetic hydrocarbon fluids. It exhibits low temperature performance to temperatures of −40 degrees Fahrenheit and has been formulated with an additive package which insures high film strength, EP, corrosion protection, and anti-wear properties. This grease is used for grease filled industrial gear cases, subject to high temperatures. Duralube EP-0, EP-1, and EP-2 are lithium complex greases formulated with quality base oils and fortified with rust and oxidation inhibitors as well as EP additives. They are water resistant greases and have a dropping point of over 500 degrees Fahrenheit allowing them to perform at high temperatures.

The Over Base Calcium Sulfonate grease, such as Alpha 2000, may come in different grades, such as EP1 or EP2, etc. It is a calcium based grease that performs at extremely high temperatures. For instance, Alpha 2000 does not become fluid at temperatures approaching 600° F. and after cooling to room temperature, it returns to its original grease structure. Alpha 2000 may be used in a variety of applications for automotive, industrial, construction, agricultural, railroad, and mining operations. Specific applications include all chassis points for automotive, wheel bearings, fifth wheels, king pins, anti-friction bearings, low and high speed journal bearings, oven conveyors, electric motor bearings, steel mill roller bearings, and on form and earth-moving equipment. Alpha 2000 is also excellent for use in marine type applications where water washout and corrosion are of primary concern. The benefits of using an Over Base Calcium Sulfonate grease include water resistance and corrosion protection. It contains no heavy metals or other harmful or environmentally undesirable additives such as sulfur, phosphorus, chlorine, zinc, phenols, antimony, barium or lead.

In at least one embodiment according to the present disclosure, the method 300 includes the step of adding a first quantity of the at least one base oil 306 to a first quantity of the at least one grease 308 in a mixing container 310. The mixing container may include, but is not limited to, a metal or plastic drum, vat, or container. In particular, a stainless steel or aluminum vat, drum, or container may be used.

In at least one embodiment according to the present disclosure, the method 300 includes the step of adding a copper powder to the mixing container, wherein the copper powder comprises at least one spherical particle 314. The copper powder may include, but is not limited to, copper powder purchased from ACuPowder International, LLC (MSDS Number C-801 Copper Powder-American Chemet Corporation (Chem Copp 1700 FPM)). The Copper 1700 FPM has a D50 in the range of about 8.0 μm to 13.0 μm. The spherical shaped copper powder particles are about 4.0 μm to 176.0 μm in size. The percent of copper powder used may range from 0.1% up to 60.0% of the total weight of the grease.

In at least one embodiment according to the present disclosure, the method 300 includes the step of adding a bismuth powder to the mixing container, wherein the bismuth powder comprises at least one spherical particle 316. The bismuth powder may include, but is not limited to, bismuth powder purchased from ACuPowder International, LLC (MSDS Number B-101 Bismuth Powder-American Chemet Corporation (301A Bi)). The 301A Bi has a D50 in the range of about 5.0 μm to 15 μm. The spherical shaped bismuth powder particles are about 0.9 μm to 32.0 μm in size. The percent of bismuth powder used may range from 0.1% up to 60.0% of the total weight of the grease.

In at least one embodiment according to the present disclosure, the method 300 includes the step of mixing the first quantity of the at least one base oil 306, the first quantity of the at least one grease 308, the copper powder 314, and the bismuth powder 316 in the mixing container until well blended to form a lubricant composition 318. Mixing may occur at any speed fast enough to disperse the copper and bismuth powders. The mixing speed may include, but is not limited to, 500-2000 rpm, and preferably 500-1500 rpm at a temperature less than 140 degrees Fahrenheit. In at least one embodiment according to the present disclosure, the method 300 includes the step of mixing the lubricant composition 318 with a second quantity of grease 320 to form a grease lubricant 322. In another at least one embodiment of the present disclosure, the method 300 further includes the step of applying the grease lubricant to an engine comprising at least one metal surface 324. In at least one aspect of the present disclosure, the method 300 includes the step of applying heat and pressure within the engine to compress the lubricant composition, wherein compressing the lubricant composition infuses the copper powder and the bismuth powder within the lubricant composition to the at least one metal surface of the engine 326. The heat and pressure applied to the engine include normal temperatures and pressures as found under normal conditions of running an engine. The types of engines may include combustible engines, such as those within automobiles, lawn mowers, engine-generators, and other machines.

In at least one aspect of the present disclosure, the method 300 includes the step of coating the at least one metal surface of the engine with the infused copper powder and bismuth powder 328. The application of heat and pressure within the engine to infuse the copper powder and bismuth powder 326 coats the at least one metal surface of the engine. After coating the at least one metal surface of the engine with the infused copper powder and bismuth powder 328, the at least one metal surface of the engine has a bronze color from the impregnated particles of copper and bismuth. The grease lubricant plates the friction surfaces filling in minor imperfections, scratches and scars in the metal surfaces being treated, making a smooth surface reducing friction and reducing wear from taking place. The grease lubricant acts as millions of microscopic ball bearings providing a barrier between two metal surfaces reducing metal on metal contact, which is the main cause of wear and friction. It also provides a detergent/cleaning action as it circulates through the engine and scrubs away oil sludge and deposits built up on components, restoring engine cavities to like new cleanliness.

A Synthetic EP 00 grease lubricant as produced from the present disclosure is a EP grease formulated with synthetic hydrocarbon fluids. It contains a lithium complex with EP and anti-wear additives with a low operating temperature of −40 degrees Fahrenheit and also operates at very high temperatures. It provides excellent corrosion protection and extends component life, and reduces heat and friction to provide savings in maintenance and energy costs. This product is ideal for industrial gear boxes, cycloidal gear reducers, robotic gear boxes, high speed ball or roller bearings, wire rope and cables, mining and construction applications where semi-fluid grease is used. It is successful in wheel bearings where heavy weight gear oils are currently being used. It provides superior lubrication and mobility like a gear oil but is thick enough not to leak out of seals.

An EP 0 grease lubricant as produced from the present disclosure is designed as a multi-purpose grease that is fortified with EP additives, and rust and oxidation inhibitors. It is water resistant and has a wide operating temperature of −67 degrees Fahrenheit to over 302 degrees Fahrenheit. EP 0 grease lubricants are ideal for use in severe cold applications where superior protection is important and there is a need for a thin grease. It is also used in auto greasing applications that call for an EP 0 grease for use in any industry. It is an ideal grease for increasing performance and reducing maintenance and energy costs.

A resulting EP 1 grease lubricant as produced from the present disclosure is an EP grease designed as a multi-purpose grease fortified with EP additives and rust and oxidation inhibitors. It is water resistant and has a wide operating temperature of −49 degrees Fahrenheit to over 320 degrees Fahrenheit. It is an ideal grease for increasing performance and reducing maintenance and energy costs. EP 1 grease may be used in cold applications where superior protection is important and where there is a need for a thinner grease and is applicable in any industry, including in auto-greasing applications.

A resulting EP 2 grease lubricant as produced from the present disclosure is an EP grease designed as a multi-purpose grease that is fortified with EP additives and rust and oxidation inhibitors. It is water resistant and has a wide operating temperature of −40 degrees Fahrenheit to over 302 degrees Fahrenheit. It is an ideal grease for increasing performance and reducing maintenance and energy costs. EP 2 grease may be used in applications including, but not limited to, universal joints, gear boxes, wheel bearings, axles, bushings, electric motor bearings, conveyors, 5^(th) wheel plates, and winches. This grease can be used in industries from domestic to industrial, construction, mining, manufacturing, commercial, transportation, utilities, and any application where grease is currently used.

The benefits of the Synthetic EP 00, EP 0, EP 1, and EP 2 grease lubricants include, but are not limited, resistance to water washout, reducing operating temperatures, reducing energy costs, wide operating temperature range (from −40 degrees Fahrenheit to 450 degrees Fahrenheit), extending lubrication periods, protection against rust and oxidation, extending bearing life and increasing reliability, reducing wear and scoring on all component surfaces, keeping equipment operating at peak performance, reducing friction and proving higher performance under load, and protecting against lubrication starvation through plating action. The greases as taught in the present disclosure do not contain any lead, PTFE, chlorinated paraffins, or antimony components.

FIG. 4 shows another exemplary embodiment of an engine lubricant of the present disclosure. FIG. 4 is a flow diagram of a method 400 for producing an engine lubricant according to at least one embodiment of the present disclosure. Specifically, the engine lubricant disclosed in FIG. 4 is directed to the method of producing a spray lubricant 400. In at least one embodiment according to the present disclosure, the method 400 includes the step of selecting at least one base oil 402. In at least one embodiment according to the present disclosure, the method 400 includes the step of select at least one grease 404. In at least one embodiment according to the present disclosure, the method 400 includes the step of adding a first quantity of the at least one base oil 406 to a first quantity of the at least one grease 408 in a mixing container 410. The mixing container may include, but is not limited to, a metal or plastic drum, vat, or container. In particular, a stainless steel or aluminum vat, drum, or container may be used.

In at least one embodiment according to the present disclosure, the method 400 includes the step of adding a copper powder to the mixing container, wherein the copper powder comprises at least one spherical particle 414. The copper powder may include, but is not limited to, copper powder purchased from ACuPowder International, LLC (MSDS Number C-801 Copper Powder-American Chemet Corporation (Chem Copp 1700 FPM)). The Copper 1700 FPM has a D50 in the range of about 8.0 μm to 13.0 μm. The spherical shaped copper powder particles are about 4.0 μm to 176.0 μm in size. The percent of copper powder used may range from 0.1% up to 60.0% of the total weight of the spray lubricant.

In at least one embodiment according to the present disclosure, the method 400 includes the step of adding a bismuth powder to the mixing container, wherein the bismuth powder comprises at least one spherical particle 416. The bismuth powder may include, but is not limited to, bismuth powder purchased from ACuPowder International, LLC (MSDS Number B-101 Bismuth Powder-American Chemet Corporation (301A Bi)). The 301A Bi has a D50 in the range of about 5.0 μm to 15 μm. The spherical shaped bismuth powder particles are about 0.9 μm to 32.0 μm in size. The percent of bismuth powder used may range from 0.1% up to 60.0% of the total weight of the spray lubricant.

In at least one embodiment according to the present disclosure, the method 400 includes the step of mixing the first quantity of the at least one base oil 402, the first quantity of the at least one grease 404, the copper powder 414, and the bismuth powder 416 in the mixing container until well blended to form a lubricant composition 418. Mixing may occur for any period and time and at any speed fast enough to disperse the copper and bismuth powders. The mixing speed may include, but is not limited to, 500-2000 rpm, and preferably 500-1500 rpm at a temperature less than 140 degrees Fahrenheit. The lubricant composition may comprise, but is not limited to, either the finished gear oil lubricant or the finished engine oil lubricant as taught in the present disclosure.

In at least one embodiment according to the present disclosure, the method 400 includes the step of mixing the lubricant composition with mineral spirits to form a spray lubricant 420. In at least one exemplary embodiment, the lubricant composition comprises 50% of the total weight of the spray lubricant and the mineral spirits comprise 50% of the total weight of the spray lubricant. The mixture must be continually mixed while filling containers with spray lubricant. The resulting composition may then be applied to any application requiring lubrication and where there is metal on metal movement in a low eight, low compression application, including but not limited to, hinges, overhead doors and tracks, air tools and impact wrenches, lawn mowers chains and cables, rusted nuts and bolts, high speed bearings rollers, bushings, moving parts on conveyors, hand tools, trimmers blades, etc. In addition, the spray lubricant can be used in applications such as on a dry film lubricant.

The spray lubricant applies quickly and evenly to penetrate, cover and protect against all types of friction. The spray lubricant is a solvent, allowing the product to reach into hard to reach places, helping to break free metal surfaces that are seized together and lubricates components as they break free. When used on surfaces at a higher temperatures, the faster the product will penetrate. The spray lubricant significantly reduces metal wear conditions and lowers the coefficient of friction arising under extreme pressure conditions that cause metallic adhesion, abrasion, contact fatigue and fretting. The benefits of the spray lubricant include, but are not limited to, reducing corrosion, self-repairing worn surfaces, producing protective film deposits on high wear parts, reducing operating temperatures, reducing wear on all treated components, allowing for high loads, high speed with less effects of wear, and significantly extending equipment life with less maintenance. The spray lubricant does not contain any lead, PTFE, chlorinated paraffins, or antimony components.

The use of the lubricants according to the present disclosure in engines delivers outstanding wear resistance, improves gas mileage, extends interval times needed for oil changes, and also reduce engine exhaust emission. The use of the lubricants according to the present disclosure result in an extremely high Timken wear test, over 90 pounds (values higher than 35 pounds indicate the presence of an EP additive). In addition, numerous tests have been conducted using the disclosed grease lubricant composition.

As shown in Table 1, regular Duralube grease was tested as a control against Duralube made according to the present disclosure (Duralube with Copper #1). The Duralube with Copper #1 contains a 8.55% of total weight of Copper and a 5.70% of total weight of Bismuth. 4-Ball wear tests were conducted on engines using both grease lubricants. Use of the Duralube with Copper #1 grease lubricant reduced engine wear scar from 0.60 to 0.43. This indicates that the grease lubricant of the present disclosure is capable of reducing wear and tear by 28.33% when compared to normal grease lubricants. In additional, the 4-Ball weld test shows a 100% increase in the load carrying capacity, indicating a high anti-wear capability. The reduction in wear means that operating temperatures can be reduced to reduce friction. Moreover, use of such a grease lubricant will reduce energy consumption, either fuel economy or electricity, depending on the application. These results should be similar when used in an engine or gear box.

TABLE 1 Duralube EP-2 compared to sample of Duralube with Copper and Bismuth Test Duralube EP-2 Duralube with Copper #1 Thickener Lithium Complex Lithium Complex Appearance Amber Smooth Dark Brown Smooth Dropping Point 478° F. 456° F. ASTM D 2265 Worked Penetration 278 293 60 strokes ¼ cone ASTM D 217 4-Ball weld ASTM D 2596 Pass 200 Kgf 400 Kgf Weld 250 Kgf 500 Kgf 4-Ball wear 0.60 mm 0.43 mm ASTM D 2266 A Oil Separation 2.4% loss 6.3% loss ASTM D 1742 Hegman 10 Micron 10 Micron

Similarly, Table 2 shows a comparison of SLC HV 00 grease, which has a thin consistency and is similar to a thick oil, such as engine or gear oil. The base grease was tested against different compositions of the grease lubricant as taught in the present disclosure. The Copper #1 composition contains 8.55% of the total weight of Copper and a 5.70% of the total weight of Bismuth. Samples 1-3 also contain different percentages of Copper and Bismuth according to the present disclosure. Sample 1 contains 9.0% of the total weight of Copper and 13.0% of the total weight of Bismuth. Sample 2 contains 4.5% of the total weight of Copper and 13.0% of the total weight of Bismuth. Sample 3 contains 0.0% of the total weight of Copper and 13.0% of the total weight of Bismuth. While Copper #1 and Samples 1-3 all resulted in better results for the 4-Ball weld and wear tests than the SLC HV 00 control, the composition of Copper #1 had the best performance.

TABLE 2 SLC HV 00 Compared with Copper #1, Sample 1, Sample 2, and Sample 3 Test SLC HV 00 Copper #1 Sample 1 Sample 2 Sample 3 Thickener Lithium Cx Lithium Cx Lithium Cx Lithium Cx Lithium Cx Appearance Purple, smooth Dark Brown Dark Brown Dark Brown Dark Brown Worked Penetration 427 422 418 421 412 60 strokes ¼ cone ASTM D 217 4-Ball weld ASTM D 2596 Pass 200 Kgf 400 Kgf 400 Kgf 400 Kgf 400 Kgf Weld 250 Kgf 500 Kgf 500 Kgf 500 Kgf 500 Kgf 4-Ball wear 0.59 mm 0.41 mm 0.45 mm 0.44 mm 0.48 mm ASTM D 2266 Hegman A 5 Micron 18 Micron 14 Micron 18 Micron 11 Micron

Example 1 Engine and Gear Oil Lubricant Formulations

Raw material Wt % Lbs Pre-Mix Base Oil 21.00 105.00 Chemtool EP#2 Grease 10.50 52.50 Bismuth 301A 6.50 32.50 Copper 1700FPM 8.50 42.50 Total 46.50 232.50 Remaining Base Oil 53.50 267.50 Total 100% 500.00

For manufacturing a volume of 500 pounds of either engine or gear oil, 105 pounds of an EP base oil is added to a Chemtool EP#2 Grease containing a Lithium complex and mixed at high speed for 20 minutes. After mixing, 32.50 pounds of Bismuth 301A and 42.50 pounds of Copper 1700FPM are added to the mixture of grease and oil and mixed at high speed for 45 minutes. After mixing, an additional 267.50 pounds of base oil is added and mixed for 20 minutes. The resulting composition may then be bottled and used in internal combustible engines.

Example 2 Grease Lubricant Formulation

Raw material Wt % Lbs Pre-Mix Synative ES 2900 Oil 3.51 28.07 NLGI #2/00 Grease 5.04 40.35 Bismuth 301A 5.70 45.61 Copper 1700FPM 8.55 68.42 Total 22.8% 182.46 Remaining NLGI #2/00 Grease 77.19 617.54 Total  100% 800.00

For manufacturing a volume of 800 pounds of grease lubricant, 40.35 pounds of NLGI #2/grease was added to 28.07 pounds of Synative ES 2900 oil, 45.61 pounds of Bismuth 301A and 68.42 pounds of Copper 1700FPM and mixed until smooth. After mixing, an additional 617.54 pounds of NLGI #2/00 grease is added and mixed until smooth. The resulting composition may then be bottled and used in internal combustible engines.

Example 3 Spray Lubricant Formulation

Raw material Wt % Lbs Gear/Engine Lubricant 50.0 250.00 Mineral Spirits 50.0 250.00 Total 50.0% 500.00

For manufacturing a volume of 500 pounds of spray lubricant, 250 pounds of either a finished gear oil treatment or engine oil treatment as taught in the present disclosure is added to 250 pounds of mineral spirits and mixed for 5-10 minutes. The mixture must be continued to be mixed while filling containers with spray lubricant. The resulting composition may then be applied to any application requiring lubrication.

While various embodiments of engine lubricant and methods for using the same have been described in considerable detail herein, the embodiments are merely offered by way of non-limiting examples of the disclosure described herein. It will therefore be understood that various changes and modifications may be made, and equivalents may be substituted for elements thereof, without departing from the scope of the disclosure. Indeed, this disclosure is not intended to be exhaustive or to limit the scope of the disclosure.

Further, in describing representative embodiments, the disclosure may have presented a method and/or process as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. Other sequences of steps may be possible. Therefore, the particular order of the steps disclosed herein should not be construed as limitations of the present disclosure. In addition, disclosure directed to a method and/or process should not be limited to the performance of their steps in the order written. Such sequences may be varied and still remain within the scope of the present disclosure. 

We claim:
 1. A lubricant comprising: a base oil; a grease; a copper powder, comprising at least one spherical particle; a bismuth powder, comprising at least one spherical particle.
 2. The lubricant of claim 1, wherein the copper powder is between 0.1% and 60% of the total weight of the lubricant.
 3. The lubricant of claim 1, wherein the bismuth powder is between 0.1% and 60% of the total weight of the lubricant.
 4. The lubricant of claim 1, wherein the lubricant is an engine oil.
 5. The lubricant of claim 4, wherein the base oil comprises a shear stabile polymer and at least one additive.
 6. The lubricant of claim 1, wherein the lubricant is a gear oil.
 7. The lubricant of claim 6, wherein the base oil comprises a top-treat additive package.
 8. The lubricant of claim 1, wherein the lubricant is a grease.
 9. The lubricant of claim 8, wherein the grease comprises a synthetic lubricating grease comprising a lithium complex.
 10. The lubricant of claim 1, wherein the lubricant is a spray lubricant.
 11. The lubricant of claim 1, wherein the at least one spherical particle of the copper powder is about 4.0 μm to 176.0 μm in size.
 12. The lubricant of claim 11, wherein the D50 particle size of the at least one particle of the copper powder is about 8 μm to 13 μm.
 13. The lubricant of claim 1, wherein the at least one spherical particle of the bismuth powder is about 0.9 μm to 32.0 μm in size.
 14. The lubricant of claim 13, wherein the D50 size of the at least one particle of the bismuth powder is about 5.0 μm to 15 μm.
 15. A method for producing a lubricant, the method comprising the steps of: selecting at least one base oil; selecting at least one grease; adding a first quantity of the at least one base oil to a first quantity of the at least one grease in a mixing container; adding a copper powder to the mixing container, wherein the copper powder comprises at least one spherical particle; adding a bismuth powder to the mixing container, wherein the bismuth powder comprises at least one spherical particle; mixing the first quantity of the at least one base oil, the first quantity of the at least one grease, the copper powder, and the bismuth powder in the mixing container until well blended to form a lubricant composition.
 16. The method of claim 15, further comprising the step of mixing the first quantity of the at least one base oil and the first quantity of the at least one grease in the mixing container prior to adding the copper powder and bismuth powder to the mixing container.
 17. The method of claim 16, further comprising the step of mixing the lubricant composition with a second quantity of the at least one base oil to form an engine or gear oil lubricant.
 18. The method of claim 17, wherein the first quantity of the at least one base oil and the first quantity of the at least one grease is mixed in the mixing container at a high speed for 20 minutes; wherein the first quantity of the at least one base oil, the first quantity of the at least one grease, the spherical copper powder, and the spherical bismuth powder are mixed in the mixing container at a high speed for 45 minutes; and wherein the lubricant composition and the second quantity of the at least one base oil are mixed in the mixing container for 20 minutes.
 19. The method of claim 16, further comprising the step of mixing the lubricant composition with a second quantity of the at least one grease to form a grease lubricant.
 20. The method of claim 15, further comprising the steps of: applying the lubricant composition to an engine comprising at least one metal surface; applying heat and pressure within the engine to compress the lubricant composition, wherein compressing the lubricant composition infuses the copper powder and the bismuth powder within the lubricant composition to the at least one metal surface of the engine; and coating the at least one metal surface of the engine with the infused copper powder and bismuth powder.
 21. The method of claim 15, further comprising the step of mixing the lubricant composition with mineral spirits to form a spray lubricant. 